Cross-polar compensating feed horn and method of manufacture

Abstract

A feed horn with a horn body and a waveguide body, each with a front end and a back end, respectively. The horn body and the waveguide body coupled together, the waveguide body front end to the horn body back end. The waveguide body provided with a waveguide bore between the front end and the back end. At least one slot formed in the waveguide bore parallel to a longitudinal axis of the body bore, the at least one slot extending to the front end. The horn body provided with a horn bore between the front end and the back end. The horn body and the waveguide body formable via injection molding methods such as die casting.

1. A feed horn, comprising:
 a horn body and a waveguide body, each with a front end and a back end, respectively; 
 the horn body and the waveguide body coupled together, the waveguide body front end to the horn body back end; 
 the waveguide body provided with a waveguide bore between the front end and the back end; 
 at least one slot formed in a sidewall of the waveguide bore generally parallel to a longitudinal axis of the waveguide bore; 
 the at least one slot extending to the front end; 
 the horn body provided with a horn bore between the front end and the back end, the horn bore at the back end provided with a diameter equal to or less than the waveguide bore at the front end, wherein the at least one slot has a depth greater than a first step of the horn bore. 
 
     
     
       2. The feed horn of  claim 1 , wherein the horn bore is provided with a plurality of steps increasing a horn bore diameter between the back end and the front end. 
     
     
       3. The feed horn of  claim 2 , wherein at least one of the steps further includes an annular groove open to the front end. 
     
     
       4. The feed horn of  claim 1 , wherein the waveguide bore extending to the back end has a smaller diameter than a compensation portion of the waveguide bore extending to the front end. 
     
     
       5. The feed horn of  claim 4 , wherein the at least one slot is in the compensation portion. 
     
     
       6. The feed horn of  claim 1 , wherein the at least one slot is a plurality of slots, each generally parallel to the longitudinal axis. 
     
     
       7. The feed horn of  claim 1 , wherein the horn body and the waveguide body are coupled together by at least one fastener. 
     
     
       8. The feed horn of  claim 1 , wherein the horn body and the waveguide body are coupled together with the body bore coaxial with the horn bore. 
     
     
       9. A method for manufacturing a feed horn, comprising the steps of:
 forming a horn body and a waveguide body, each with a respective front end and a back end; 
 the waveguide body formed with a waveguide bore between the front end and the back end; at least one slot formed in the waveguide bore extending to the front end, parallel to a longitudinal axis of the waveguide bore; and 
 coupling the horn body and the waveguide body together, the waveguide body front end to the horn body back end, wherein the at least one slot is formed with a depth greater than a first step of the horn bore. 
 
     
     
       10. The method of  claim 9 , wherein the horn bore is formed with a diameter at the back end equal to or less than the waveguide bore at the front end. 
     
     
       11. The method of  claim 9 , wherein the waveguide bore extending to the back end has a smaller diameter than a compensation portion of the waveguide bore extending to the front end. 
     
     
       12. The method of  claim 11 , wherein the at least one slot is formed in the compensation portion. 
     
     
       13. The method of  claim 9 , wherein the coupling of the horn body and the waveguide body together is via overmolding either the horn body upon the waveguide body or the waveguide body upon the horn body, creating a monolithic feed horn. 
     
     
       14. The method of  claim 9 , wherein the waveguide body and the horn body are formed via die casting. 
     
     
       15. The method of  claim 9 , wherein the waveguide body and the horn body are formed via injection molding. 
     
     
       16. The method of  claim 9 , wherein the waveguide body and the horn body are formed via thixotropic molding. 
     
     
       17. The method of  claim 9 , wherein the waveguide body and the horn body are formed via metal injection molding.